Filler metal with flux for brazing and soldering and method of making and using same

ABSTRACT

A wire ( 10 ) for use in a brazing or soldering operation has an elongated body ( 12 ) of a metallic material. The elongated body ( 12 ) has an outer surface ( 18 ). A channel ( 14 ) is formed along a length of the body. The channel ( 14 ) has an opening (A 1 ). A flux solution ( 22 ) is deposited within the channel ( 14 ) and along the length of the body. The flux solution ( 22 ) covers a portion of the outer surface ( 18 ). A portion of the flux solution ( 22 ) is exposed through the opening (A 1 ) in the channel ( 14 ).

RELATED APPLICATION

This Application claims the benefit of Provisional Patent ApplicationSer. No. 60/808,416 filed May 25, 2006.

TECHNICAL FIELD

The invention relates to relates to wire used in brazing and soldering.More particularly, the present invention is directed to a channeled wirehaving a flux solution deposited therein for use in joining two similaror dissimilar metals in industrial applications.

BACKGROUND OF THE INVENTION

Brazing and soldering are two methods commonly used to join two similaror dissimilar metals together. These processes typically involve joiningmetal components together by disposing a brazing composition such as analuminum or metal alloy adjacent to or between the faying surfaces,i.e., the surfaces to be joined. The brazing filler alloy and the fayingsurfaces are then heated to the brazing temperature, typically above themelting temperature of the braze alloy but below the melting temperatureof the components to be joined. The brazing composition then melts,flows into the joint by capillary action and forms a fillet and sealthat bonds the faying surfaces.

In most cases, these processes require a chemical flux in addition tothe filler alloy. The flux prepares the base metals to accept the filleralloy which results in a strong bond. Fluxes are generally grouped undertwo categories: corrosive (must be removed) and non-corrosive (residuesare left on the part).

Historically, the alloy and flux are applied as two separate steps. Inrecent years however, an increasing number of options have beendeveloped that combine the filler alloys and fluxes in one completeform. These developments have taken place with brazing alloys that arealuminum based and silver based.

For instance, Omni Technologies Corporation (Epping, N.H.) developed aflux core wire, which is sold under the trademark SIL-CORE™. In order toaccomplish this, Omni takes aluminum in the form of narrow sheet,deposits a quantity of powdered flux down the middle, and then formrolls the narrow sheet around the flux. This material is then putthrough draw dies to reduce the diameter and compact the flux inside.From this process, Omni offers several wire diameters as well asdifferent flux compositions. In addition, the amount of flux can bechanged as needed. This material is available on spools, large coils andcustom fabricated shapes. The inventors of the present invention believeOmni uses a flux sold by Solvay Chemical Company under the nameNOCOLOK®. NOCOLOK® brand is one of the most widely recognizednon-corrosive aluminum fluxes. This product is described in U.S. Pat.No. 5,781,846, which is hereby incorporated by reference as if fully setforth herein. Omni claims the SIL-CORE™ product does not contain abinding agent.

The S.A. Day Corporation (Buffalo, N.Y.) produces an aluminum fluxcoated rod sold under name DAYROD. This rod includes an aluminum wirecut to 12 inch rods, and dipped in an aluminum flux bath. After dipping,the rods are hung to dry. Day does not use NOCOLOK® brand flux. Instead,Day uses a similar formulation which is mixed with a polymer-basedbinder system. This binder allows for the flux to remain ductile and notbrittle. The flux coated rods can be bent or twisted and the flux willnot fall off.

Day also produces a flux coated ring. Day purchases metallic rings fromBellman-Melcor, Inc. The rings are then loaded on a machine that“paints” a thin coating of flux on the outside edge of each ring. Whilethe end product is acceptable, it is very slow to produce andconsequently very expensive. Similar to the rods, the rings can behandled roughly and the flux remains intact.

Protechno-Richard (France) offers a product very similar to the Omniproduct.

Kin-Met (Korea) produces an extruded product. A powdered form ofaluminum braze alloy is mixed with powdered flux. The combination ispressurized and extruded into final form.

Wolverine and Omni teamed up to create a flux coating for silver basedmaterials. Made from a ductile binder system, this technology is soldunder the name SILVACOTE™. SILVACOTE™ is a continuously coated,flux-coated brazing material.

The present invention is provided to solve the problems discussed aboveand other problems, and to provide advantages and aspects not providedby prior brazing wires of this type. A full discussion of the featuresand advantages of the present invention is deferred to the detaileddescription, which proceeds with reference to the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention is directed to a wire for use in a brazing orsoldering operation. The wire comprises an elongated body, a channel,and a flux solution. The elongated body is produced from a metallicmaterial. The body has an outer surface. The channel is formed along atleast a portion of the body. The channel has an opening. The fluxsolution is deposited within the channel and along the length of thebody with a surface of the flux solution being exposed through theopening in the channel.

The metallic material may be an aluminum alloy, a silver alloy, a copperalloy, and/or a zinc alloy.

The elongated body may have a substantially elliptical cross-sectionalshape, a substantially rectangular shape cross-sectional shape, and or asubstantially kidney-shaped cross-sectional shape.

The channel may have a substantially rectangular shape.

The flux solution may be a non-corrosive or corrosive flux solution.

The flux solution may include a polymer-base binder.

The opening may be about 0.030 inches.

The opening may be about 30% to 70% of a major axis of the wire.

The channel may be about 0.020 inches deep.

The channel may have a depth of about 10% to 50% of a major axis of thewire.

The elongated body may be formed into an annular ring having an innerwall and an opposing outer wall. The channel may form a portion of theinner wall. The flux solution within the channel may form a portion ofthe inner wall, and a top surface of the flux solution within thechannel may be located below a straight line or imaginary plane spanningacross the opening of the channel. The straight line may be locatedentirely along the inner wall of the ring.

The present invention is also directed to a wire for use in a brazing orsoldering operation. The wire comprises an elongated body, a channel,and a flux solution. The elongated body is of a metallic material. Thebody has a length substantially greater than a width. The elongated bodyalso has an outer surface. The channel is formed along a portion of thelength of the body and has an opening. The flux solution is depositedwithin the channel and along the portion of the length of the body. Theflux solution covers a portion of the outer surface. A portion of theflux solution is exposed through the opening in the channel.

The invention is further directed to a method of preparing a wire foruse in a brazing or soldering operation. The method comprises the stepsof providing an elongated wire, forming a channel along at least aportion of the length of the elongated wire, and depositing a fluxsolution into the channel. The elongated wire has a length substantiallygreater than a cross-sectional width and an outer exposed surface. Thechannel has an opening. The flux solution is deposited into the channelsuch that a portion of the flux solution is exposed in the opening.

The channel may span substantially the entire length of the elongatedwire.

The opening may span substantially the length of the elongated wire.

The flux solution may comprise a metallic component and apolymeric-based component.

The polymeric-based component may be an acrylic polymer.

The metallic material may be an aluminum-based powder.

The invention is also directed to a further method of preparing a wirefor use in a brazing or soldering operation. This method comprises thesteps of: providing an elongated wire having a length substantiallygreater than a cross-sectional width and an outer exposed surface;forming a channel along at least a portion of the length of theelongated wire, the channel having an opening; depositing a fluxsolution through the opening into the channel wherein a portion of theouter surface of the elongated wire is covered by the flux solution anda portion of the flux solution is exposed in the opening; and curing theflux solution within the channel.

The method may comprise the further steps of: cutting the elongated wireto a predetermined length after the curing step; and forming an annularring of the elongated wire. The forming the annular ring step maycomprise the sub-step of creating an inner wall and an opposing outerwall, the inner wall including the channel containing the flux solution.

The depositing the flux solution step may also comprise the followingsub-steps: providing a chamber including a volume of the flux solution;passing the elongated wire through an inlet in the chamber; removing theelongated wire from the chamber through an outlet in the chamber; andpassing the wire through a die located adjacent the outlet; the diehaving a passageway therethrough wherein the shape of the passagewayregulates the amount and location of the flux solution left on theelongated wire.

The curing step may include the step of: providing a source of power;and electrically connecting the elongated wire to the source of power.

Another aspect of the present invention is directed to a wire for use ina brazing or soldering operation. The wire comprises an elongated bodyof a metallic material, a channel formed along a length of the elongatedbody, the channel having an opening, and a flux solution within thechannel, the flux solution comprising a flux material and bindermaterial.

The binder material may be a polymer-base material. The polymer-basematerial may comprise a polymer selected from a group consisting of anacrylic polymer and a polymer produced from copolymerization of carbondioxide. The polymer may be a poly alkylene carbonate.

The flux material may be aluminum-based or cesium-based.

The metallic material of the elongated body may be an aluminum alloy, orthe metallic material may be a zinc/aluminum alloy comprising at leasthaving at least 2 percent by weight aluminum.

Other features and advantages of the invention will be apparent from thefollowing specification taken in conjunction with the followingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a cross-sectional view taken transverse to the length of afirst braze wire of the present invention;

FIG. 2 is a cross-sectional view taken transverse to the length of asecond braze wire of the present invention;

FIG. 3 is a cross-sectional view taken transverse to the length of athird braze wire of the present invention;

FIG. 4 is a cross-sectional view taken transverse to the length of afourth braze wire of the present invention;

FIG. 5 is a perspective view of a lengthwise section of a typical brazewire of the present invention;

FIG. 6 is a perspective view of a wire of the present invention formedinto an annular ring;

FIG. 7 is a cross-sectional view of the annular ring of FIG. 6;

FIG. 8 is a perspective view of a lengthwise section of a typical brazewire of the present invention;

FIG. 9 is a top view of the braze wire of FIG. 8 formed in the form ofan annular ring;

FIG. 10 is a schematic view of a manufacturing method of forming a wireof the present invention;

FIG. 11 is a partial cross-sectional view of a pair of work rolls forrolling a channel into an elongated wire;

FIG. 12 is a perspective view of a flux solution chamber and a die/wiperfor removing excess flux solution on a wire pf the present invention;and

FIG. 13 is a cross-sectional view of a method for joining a pair oftubular members using a wire of the present invention formed as anannular ring.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

The present invention is directed to a brazing/soldering wire for use inmultiple metal combinations including aluminum applications. The end usefor these materials is typically industrial applications, such asautomobiles and automobile component manufacturing as well as other heattransfer applications including air conditioning and refrigerationmanufacture. Of course, other applications can be had as well. Thebrazing/soldering wire of the present invention may be used on manydifferent materials including aluminum alloys, zinc alloys, copperalloys and silver alloys, etc. The wire itself can be produced from analuminum alloy, a silver alloy, a copper alloy, and/or a zinc alloy.

The Wire

The present invention includes a solid wire 10 rather than a narrowsheet or strip that is preferably very robust and will not move whenassembled onto component parts. This is important because in airconditioning applications, braze wire is commonly supplied in ring-form.The rings are friction fit or snuggly placed around tubes. Becausecurrent ring shaped braze wires often lose their grip on componentparts, causing the rings to shift or fall off altogether, rings formedfrom the wire 10 of the present invention are specifically constructedso as to be less likely to plastically deform by the friction fit aboutthe component parts. As a result, they are less likely to shift or falloff prior to the brazing or soldering process. This important aspect ofthe present invention is described in more detail below.

Referring to FIGS. 1 though 5, a wire 10 having an elongated body 12with a channel 14 reformed along a length of an outer surface 18 isillustrated. The wire 10 is formed from a metallic material supplied ata diameter of about 0.031 inches to 0.125 inches (0.787 mm to 3.18 mm),preferably 0.079 inches to 0.090 inches (2.00 mm to 2.29 mm), or anyrange or combination of ranges therein. The wire 10 has been rolled orreformed to a new geometric shape, such as substantially rectangular orelliptical configuration having a major axis D₁ of about 0.105 inches(2.67 mm) and a minor axis C₁ of about 0.048 inches (1.22 mm). Theoverall shape of the reformed wire 10 may also be described askidney-shaped, U-shaped, or C-shaped in cross-section. A discontinuity20 in the outer surface 18 and, thus the shape of the wire 10, is causedby the channel 14 formed therein. It would be appreciated by one ofordinary skill in the art that dimensions of the wire 10 may varygreatly based on customer requirements.

The channel 14 typically has a substantially rectangular or conicsection shape having an opening A₁ of about 0.030 inches (0.76 mm) and adepth B₁ of about 0.020 inches (0.51 mm). Preferably, the opening A₁ isabout 30% to 70% of the starting diameter of the wire or a major axis ofthe reformed wire, and the channel 14 has a depth B₁, about 10% to 50%of the starting diameter of the wire or a major axis of the reformedwire. Again, it would be appreciated by one of ordinary skill in the artthat dimensions of the channel 14 may vary greatly based on customerrequirements.

The channel 14 is at least partially filled with a volume of fluxsolution 22. The volume of flux solution 22 per length of the wire 10 isdetermined by the end use for the wire. However, it is preferable forthe entire volume of flux solution 22 to be positioned within thechannel 14 and for the flux solution to be exposed through the openingin the channel 14. Thus, the remaining portions of the outer surface 18of the wire are free of flux solution 22. A top surface of the fluxsolution 22 is preferably located below an imaginary line or plane 24spanning the uppermost surface of the opening A₁ of the channel 14. (SeeFIG. 3).

The flux solution 22 preferably comprises a polymer-based bindercombined with a flux material. Because the flux solution 22 includes apolymer-based binder, the wire 10 may be manipulated into virtually anyshape without disturbing the flux solution 22. Thus, the wire 10 of thepresent invention may be provided on spools, coils, straight rods andmost importantly made to order custom performs, such as rings and thelike. The wire 10 may further be supplied in unlimited wire sizes withdifferent flux formulations as well as different alloy/flux ratios.

Referring to FIGS. 6-7, a wire 10 of the present invention has beenformed into a perform. The perform may be a rod, slug, or any othercustom shape. In the embodiment illustrated the perform is an annularring 30. The ring 30 is formed such that the channel 14 bearing the fluxsolution 22 forms an inner wall 32 of the ring 30. An outer wall 34 ofthe ring 30 is free of flux solution 22. By locating the flux/polymersolution 22 on the inner wall of the ring 30, two advantages arerealized. First, the flux, within the flux solution 22, is locatedadjacent one of the parts to be joined. Second, the flux solution 22 isin compression, rather than tension, wherein the solution 22 tends toremain within the channel 14 rather than flaking, pealing, or otherwisefalling off of the wire 10.

Further to the structure of the inner wall of the ring 30, the imaginarystraight line or plane 24, of which the top surface of the flux solution22 is preferably below, is located entirely along the inner wall 32 ofthe ring 30. Thus, the opening A₁ of the channel 14 is also locatedentirely along the inner wall 32 of the ring 30. In other words, theflux solution 22 forms a portion of the inner wall 32. Moreparticularly, the top surface of the flux solution 22 forms at least aportion of the inner wall 32.

Referring to FIG. 8, an alternative embodiment of a wire 10 of thepresent invention is illustrated. In this embodiment, a plurality ofchannels 14 are formed in the wire 10. The channels 14 are formed alonga transverse length of the elongated body 12. In other words, the lengthof the wire 10 forming the channel 14 is transverse to the elongatedbody 12 of the wire 10. Each channel 14 is otherwise as described above,each channel 14 being at least partially filled with a flux solution 22,preferably filled to a height below the imaginary line or plane 24. Theshapes and dimensions of the wire 10 are, likewise, as described above.

FIG. 9 is an illustration of the wire 20 of FIG. 8 reformed to anannular ring 30. The ring 30 is formed such that the channel 14 bearingthe flux solution 22 forms an inner wall 32 of the ring 30. In thisexample, the outer wall 34 of the ring 30 includes a section or portionof each channel 14 and thus the flux solution 22 within each channel 22also forms a portion of the outer wall 34 of the ring 30. Thisconfiguration achieves the advantages of the previous embodiment as wellas the additional benefit that upon melting or liquefying, the flux inthe flux solution 22 is free to flow from each channel 14 in a directiontransverse to the length of the elongated body 12. It would beappreciated by one of ordinary skill in the art that the channels 14 maybe completely contained along the inner wall 32 of the ring, similar tothe single channel 14 of the FIGS. 6-7, or that some percentage of thechannels 14 may be completely contained along the inner wall 32 of thering 34 with some percentage of the channels 14 forming a portion ofboth the inner and outer walls 32,34 of the ring. It would be stillfurther appreciated by one of ordinary skill that some percentage of thechannels 14 may be completely contained on the inner wall 32, that somepercentage of the channels 24 may be completely contained on the outerwall 34, and that some percentage of the channels 14 may form a portionsof the inner and outer wall 32,34 of the ring 30. In other words, thechannels 14 may be distributed about the circumference of the outersurface 18 of the elongated body 12.

There are several advantages of the wire of the present invention. Forexample, the raw material is cheaper and the process speed issignificantly faster than any other product combining wire and flux. Ascompared to the Omni product, the wire 10 of the present inventionincludes a flux solution 22 which is exposed along a length of the wire10. The flux solution 22 is not encased. As a result, this allows theflux within the flux solution 22 to melt and release from the wire priorto the alloy of the wire melting.

The Flux Solution

The flux solution 22 is preferably prepared in the following manner. Agranulated or beaded polymer is first dissolved in a solvent to form aliquefied suspension. The polymeric material may be derived from anacrylic polymer, such as a proprietary acrylic polymer manufactured byS.A. Day Mfg. Co. The polymeric material, however, is preferably derivedfrom a carbon dioxide rather than a petroleum; it is enzyme degradable;and it is biocompatible where thermal decomposition yields a carbonatewhich vaporizes for complete removal, leaving minimal ash residue. Theproducts of combustion are non-toxic (primarily carbon dioxide andwater). Accordingly, the polymer is generally a thermoplastic,preferably a copolymer, more preferably a poly alkylene carbonateproduced through the copolymerization of CO₂ with one or more epoxides.

Once the polymer is dissolved in the solvent, a flux is then added inpowder form. Any suitable flux, corrosive and non-corrosive, can be useddepending on the desired end use. The resulting solution is a thick,homogeneous mixture having a paste-like consistency similar to caulk.

The Method of Manufacture

As illustrated in FIGS. 10-12, the channel 14 is formed by a rollforming operation. A rolling mill 100 having an upper roll 102 and acomplementary lower roll 104 imparts a specific, pre-designed shape tothe wire 10. The profile of the upper and lower rolls 102,104 isdetermined by the characteristics desired by the rolled wire, i.e.designed to accommodate a specific volume of flux required per length ofwire or flux/wire metal ratio. In short, the profiles of thecomplementary rolls 102,104 form the wire's profile at the bite of therolls 102,104, and the rolls 102,104 may be changed for differentprofiles desired.

As the wire 10 exits the rolling operation, the flux solution 22 isadded to the channel 14. This is accomplished by inserting the fluxsolution 22 within a dispensing cartridge 108. An external source ofpressure, shown schematically at reference number 112, forces thesolution 22 from the cartridge 108 to a holding chamber or die chamber116 wherein a bath of the solution 22 is generated within the chamber116. The amount of flux solution 22 forced from the cartridge 108 to thechamber 116 is controlled by a metering device.

The reformed wire 10 enters the chamber 116 through an opening at oneend of the chamber 116 so that the solution 22 coats the entire surfaceof the wire 10. The solution 22 also enters the channel 14 through theopening A₁ and fills, or partially fills, the channel 14 on the wire'souter surface 18. The coated wire 10 then exits the chamber 116 througha rubber wiper or die 120 which includes a shaped opening or passageway124. Excess solution 22 is wiped or cleaned as the wire 10 exits thechamber, leaving only the desired amount of flux solution 22 on the wire10, preferably only within the channel 14. In other words, the diecontrols the amount of solution left within the channel 14, distributesthe solution 22 evenly within the channel, and ensures no excesssolution 22 remains on the wire 10.

Once the channel 14 is filled with the desired volume of solution 22,the solution is dried or cured to form a solid within the channel 14.Any number of methods may be used, including ultra-violet, infra-red,heated fluid pressure, etc. In this embodiment, electrodes 128 a, 128 bare electrically connected to the coated wire 10 wherein an electriccurrent from a source of power 132 heats the wire 10 to the desiredtemperature, generally between 100° F. to 250° F. (38° C. to 121° C.),preferably between 125° F. to 175° F. (52° C. to 79° C.), mostpreferably 150° F. (66° C.), or any range or combination of rangestherein.

Once the solution is sufficiently dried, the wire 10 is spooled fordelivery or further process.

Method of Use

An example of the present invention is illustrated in FIG. 13. A firsttubular metallic part 200 is to be joined to a second tubular metallicpart 204. The first tubular part 200 is passed through a ring 30 formedof the finished wire, such as the annular ring 30 illustrated in FIGS.6-7 and 9. The flux-laden channel 14 of the ring 30 is located adjacentan outer surface 202 of the first tubular part 200. The second tubularpart 204 has a radially outwardly flared flange 208 to aid in guiding anend portion of the first tubular part 200 into the second tubular part204. Unlike rings of the prior art, the flow of the flux from the ring30 of the present invention is not restricted and flows freely uponheating so as to permit joining of the first and second tubular parts200,204 once the alloy of ring 30 melts.

In a second example, the ring 30 described in conjunction with theprevious example is an aluminum soft temper alloy such 4047 aluminum.The first and second tubular parts 200,204 are produced from aluminum oran aluminum alloy. The flux solution 22 is produced by dissolving QPAC®polymer beads manufactured by Empower Materials Inc. in a methyl ethylketone (MEK) solvent. The flux is a non-corrosive aluminum flux such asthe aluminum potassium fluoride NOCOLOK® having a melting temperature ofabout 1049° F. to 1062° F. (565° C. to 572° C.) or flux B sold by S.A.Day Mfg. Co. containing potassium tetrafluoroaluminate and cesiumtetrafluoroaluminate having a melting temperature of about 1055° F.(560° C.).

The MEK solvent is particularly useful. MEK solvent is highlyevaporative so a low heat will cure the solution 22. Thus, the flux ofthis example can be liquefied and released from the flux solution 22within the desired range of between 100° F. (38° C.) and 250° F. (121°C.), most preferably about 150° F. (66° C.), or any range or combinationof ranges therein. These ranges will sufficiently evaporate the solventwithout causing the remaining flux/polymer mix 22 to become brittle.

In a third example, the tubular parts 200,204 are of aluminum or analuminum alloy having a melting temperature of about 1150° F. to 1200°F. (620° C. to 650° C.). The wire is produced from a zinc/aluminum alloyhaving a melting temperature of about 850° F. to 950° F. (454° C. to510° C.), such as an alloy comprising at least about 2% aluminum,preferably about 65% to 85% zinc and 15% to 35% aluminum, and mostpreferably 78% zinc and 22% aluminum and having a melting temperature ofabout 900° F. (482° C.), or any range or combination of ranges therein.The channel 14 is filled with a polymer/flux blend 22 which activates atabout 788° F. to 900° F. (420° C. to 482° C.), preferably a polymer asdescribed above with a cesium-based flux in the amount of about 56% to66% cesium, 27% to 32.2% fluorine, and 8.6% to 11.4% aluminum or about6.4% silicon, or any range or combination of ranges therein. Mostpreferably, the flux solution 22 includes a cesium-based flux which hasan activation temperature of about 865° F. (463° C.), such as thoseproduced by Chemetall GmbH of Frankfurt, Germany.

While the specific embodiments have been illustrated and described,numerous modifications are possible without significantly departing fromthe spirit of the invention, and the scope of protection is only limitedby the scope of the accompanying Claims.

1. A wire for use in a brazing or soldering operation, the wirecomprising: an elongated body of a metallic material; a channel havingan opening formed along a length of the elongated body; a flux solutionwithin the channel and along at least a portion of the length of theelongated body with a surface of the flux solution being exposed.
 2. Thewire of claim 1 wherein the elongated body is formed into an annularring having an inner wall and an opposing outer wall.
 3. The wire ofclaim 2 wherein the channel forms a portion of the inner wall.
 4. Thewire of claim 3 wherein the flux solution within the channel forms aportion of the inner wall.
 5. The wire of claim 4 wherein a top surfaceof the flux solution within the channel is located below an imaginaryplane spanning across uppermost points forming the channel.
 6. The wireof claim 5 wherein the imaginary plane is located entirely along theinner wall of the ring.
 7. The wire of claim 1 wherein a width of thechannel is 30% to 70% of a major axis of the wire.
 8. A method ofpreparing a wire for use in a brazing or soldering operation comprisingthe steps of: providing an elongated wire having a length substantiallygreater than a cross-sectional width and an outer exposed surface;forming a channel in the elongated wire with an opening on an outersurface of the wire; depositing a flux solution through the opening intothe channel such that a portion of the flux solution is exposed in theopening; and curing the flux solution within the channel.
 9. The methodof claim 8 wherein the step of depositing the flux solution comprisesthe steps of: providing a chamber including a volume of the fluxsolution; passing the elongated wire through an inlet in the chamber;removing the elongated wire from the chamber through an outlet in thechamber; and passing the wire through a die located at or adjacent theoutlet having a passageway therethrough wherein the shape of thepassageway regulates the amount and location of the flux solution lefton the elongated wire.
 10. The method of claim 8 further comprising thesteps of: after the curing step, cutting the elongated wire to apredetermined length; and forming an annular ring of the elongated wire.11. The method of claim 10 wherein the forming the annular ring stepcomprises the step of: creating an outer wall and an inner wall with thechannel containing the flux solution.
 12. The method of claim 8 whereinthe curing step includes the step of: providing a source of power; andelectrically connecting the elongated wire to the source of power.
 13. Awire for use in a brazing or soldering operation, the wire comprising:an elongated body of a metallic material; a channel formed along alength of the elongated body having an opening; and a flux solutionwithin the channel comprising a flux material and binder material. 14.The wire of claim 13 wherein the binder material is a polymer-basematerial.
 15. The wire of claim 14 wherein the polymer-base materialcomprises a polymer selected from a group consisting of an acrylicpolymer and a polymer produced from copolymerization of carbon dioxide.16. The wire of claim 15 wherein the polymer is a poly alkylenecarbonate.
 17. The wire of claim 13 wherein the flux material isaluminum-based.
 18. The wire of claim 13 wherein the flux material iscesium-based.
 19. The wire of claim 13 wherein the metallic material ofthe elongated body is an aluminum alloy.
 20. The wire of claim 13wherein the metallic material is a zinc/aluminum alloy comprising atleast having at least 2 percent by weight aluminum.